The article’s primary purpose is to give a technological assessment of manufacturing complex-shaped parts using powder metallurgy. The process is considered in the example of a complex-shaped product consisting of several elements manufactured separately from the Fe-C-Cu powder mixture and then combined into a single structure. The joining was carried out by impregnation of porous structural elements with the fusion of copper-containing material. It has been demonstrated that the infiltration process is affected by many factors: porosity of structural elements, wettability of their pore channels, fluid flowability of the infiltrating material, and other factors. The research was carried out on the mass products - centrifugal pump stages for oil production. The elements compaction was carried out on hydraulic press at a pressure of 500 MPa, which ensured the average density of the parts after sintering up to 7.8-8.4 g/cm3. During sintering and impregnation, various types of defects of the pieces were detected, which were caused by the excessive thickness of the infiltrating material, different densities of the walls, and insufficient wettability in the connection zones of the elements.The investigations have shown that manufacturing complex components by prefabricating single elements and their subsequent sintering combined with infiltration is feasible. It can be done in a chamber furnace as well as with belt sintering. However, it is necessary to carefully prepare the mold before sintering, choose the infiltrating agent, and analyse possible disadvantages.

In an era of rapidly growing consumer demand and the subsequent development of production, light materials and structures with a wide range of applications are becoming increasingly important in the field of construction and mechanical engineering, including aerospace engineering. At the same time, one of the trends is the use of perforated metal materials (PMMs). They are used as finishing, decorative and structural building materials. The main feature of PMMs is the presence of through holes of a given shape and size, which makes it possible to have low specific gravity; however, their tensile strength and rigidity can vary widely depending on the source material. In addition, PMMs have several properties that cannot be achieved with solid materials; for example, they can provide considerable noise reduction and partial light absorption, significantly reducing the weight of structures. They are also used for damping dynamic forces, filtering liquids and gases and shielding electromagnetic fields. For the perforation of strips and sheets, cold stamping methods are usually used, carried out on stamping presses, particularly using wide-tape production lines. Other methods of manufacturing PMMs are rapidly developing, for example, using liquid and laser cutting. An urgent but relatively new and little-studied problem is the recycling and further efficient use of PMMs, primarily such materials as stainless and high-strength steels, titanium, and aluminum alloys. The life cycle of PMMs can be prolonged because they can be repurposed for various applications such as constructing new buildings, designing elements, and producing additional products, making them more environmentally friendly. This work aimed to overview sustainable ways of PMM recycling, use or reuse, proposing different ecological methods and applications considering the types and properties of PMM technological waste. Moreover, the review is accompanied by graphical illustrations of real examples. PMM waste recycling methods that can prolong their lifecycle include construction technologies, powder metallurgy, permeable structures, etc. Several new technologies have been proposed and described for the sustainable application of products and structures based on perforated steel strips and profiles obtained from waste products during stamping. With more developers aiming for sustainability and buildings achieving higher levels of environmental performance, PMM provides significant environmental and aesthetic advantages.

Volumetric porosity as a common defect in metal 3D printing (3DP) that can significantly impede the mechanical properties of products. Traditional methods of porosity control (microscopy) and non-destructive testing (computed tomography) usually are not applicable at the production site. In this study, sensitivity of three examined testing modalities based on acoustic methods and vibration analysis to changes in the volumetric porosity of 3DP parts was examined. Test objects were cylindrical specimens made of AlMg powder by 3DP with a gradually dosed porosity from 0.5 to 4.0%. Ultrasonic testing by through transmission showed the best accuracy using ultrasound velocity and pulse intensity parameters. Shifts of resonant frequency and spectral density and appearance of side harmonics were the manifestations of increased porosity using vibration approaches. The method comprising a loudspeaker as a vibration exciter and an optoelectronic device for remote sensing of vibration is the most attractive from the point of view of application to objects of complex geometry.

High strength fibres of carbon, boron, silicon carbide, tungsten, and other materials are widely used to reinforce metal matrix composite materials. Carbon and boron fibers are usually used to reinforce light alloys based on aluminum and magnesium. Products made from these materials are characterized by high strength and rigidity and can be used for a long time. Technological waste containing such fibres are hazardous to the environment because they are durable and have needle-like and other sharp shapes. Therefore, they must be disposed of with extreme care. A significant incentive for the processing and reuse of waste composites of this type is the relatively high cost of production of the primary fibre and the material as a whole. With the increase in the production of such materials in recent years, the need to recycle composite waste is becoming increasingly important. Three main options for primary processing are used to prepare composites for their subsequent use. They are mechanical, thermal, and chemical grinding technologies. One of the actual and practical areas of processing technology is the method of powder metallurgy. This paper presents the main stages of processing composite materials based on an aluminium matrix and B-W fibres to obtain powder compositions. The results of the studies showing the possibility of the effective use of the obtained crushed waste to manufacture concrete products and the production of cutting and grinding tools are presented.